This unit applies to a learning and assessment environment where access to normal production operations is not available . A typical environment will be for application in a VET in Schools delivery environment or other simulated or trial manufacturing environment where a high degree of supervision exists.

The unit has applications in qualifications for the broad manufacturing of plastic products where the project scope can be based upon the construction of a simple plastic item such as:, tool trays and picture frame or could extend to include the production of consumer products or moulded components.

The unit should be applied to a specific 'project'/ or task which has a defined beginning, middle and end, occurs over an extended period of time, and is reflective of the plastics manufacturing industry and/or organisation.

When delivered/assessed as part of a qualification the unit should be customised to ensure its relevance to a real or simulated work activity and related workplaces and must be delivered and assessed over a period of time.

ELEMENT

PERFORMANCE CRITERIA

1. Identify job requirements

1.1. Specifications for plastic product are identified from work instructions.

1.2. Customer requirements are recognised and identified in the product specification

1.3. Assembly and finishing requirements are identified

1.4. Health, safety and environmental hazards are identified and hazard control measures are implemented.

1.5. Materials, housekeeping and waste management needs are considered

2. Prepare for work

2.1. Equipment requirements are checked and equipment adjusted to appropriate process settings

2.2. Materials requirements are checked and adjusted as required

2.3. Records are kept according to company requirements

2.4. Pre-start checks are completed as required

2.5.

3. Operate equipment to produce component

3.1. Equipment is started up following workplace and hazard control procedures

3.2. Process is monitored to ensure quality

3.3. Product quality is monitored as required

3.4. Quality and other problems are identified and rectified

4. Complete work

4.1. Product is assembled according to specifications as required

4.2. Completed work is checked against specifications and customer requirements

4.3. Unused materials are returned to storage and waste and scrap are dealt with following workplace procedures.

4.4. Work area is cleaned; tools and equipment are returned to storage.

4.5. Documentation is completed following workplace procedures.

Required skills

communicate and work effectively and safely with others

complete a basic plastic product manufacturing project to specifications

comply with OHS&E requirements,

correct and safe use of hand tools and power equipment

comply with safety instructions and any OH&S legislation /regulations /codes of practice applicable to workplace operations

collect, organise and understand information related to basic plans

plan and organise activities

use mathematical ideas and techniques for measuring and calculation of areas and estimated materials requirements.

follow instructions and specifications and ask for help where needed

Required knowledge

workplace procedures and work instructions

quality requirements

plastics industry terminology

tool, equipment and material types and uses

plans, drawings and specifications

safety precautions with hazardous materials and equipment

organisational or workplace structure

evaluation and review procedures

creative thinking techniques

The Evidence Guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Knowledge and application of relevant sections of:

occupational, health and safety legislation; statutory legislation;

enterprise/site safety procedures;

enterprise/site emergency procedures

environmental requirements

Preparation and planning of work

Perform normal operator maintenance of work area to enable work to be conducted safely and efficiently

Relevant standards and procedures

Interpretation of work instructions and locate and apply relevant information.

Application of safe handling requirements for equipment, products and materials, including use of personal protective equipment.

Following work instructions, operating procedures and inspection practices to:

minimise the risk of injury to self or others

prevent damage to goods, equipment or products

achieve required production output and product quality.

Ability to adapt or vary plastic component designs.

Ability to construct, assemble and finish at least one basic plastic component from the list in the range statement.

Ability to work effectively with others.

Ability to modify activities to cater for variations in workplace contexts and environment.

Context of assessment

Assessment may occur on the job or in a workplace simulated facility with relevant equipment, materials, work instructions and deadlines.

Specific resources required for assessment

Access to plans, equipment, materials

Access is required to opportunities and appropriate resources to either:

Carry out a range of suitably simulated practical and knowledge assessments that demonstrate the skills and knowledge to work safely as part of a holistic assessment involving other competency units, and/or

Participate in actual workplace activities that demonstrate the skills and knowledge to work safely

The range statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the performance criteria, is detailed below. Essential operating conditions that may be present with training and assessment (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) may also be included.

What can a plastic product include?

A plastic product can include:

small container

picture frame

toys

tool box

automotive plastic products

household items

electrical goods

playground equipment

small boat

any other product made from polymers

What processes can be used to make a plastic product?

A plastic product can be made from:

injection moulding

blow moulding

thermo forming

composite

extrusion

fabrication

rotational moulding

other plastic processing methods

What are the work instructions?

Work instructions may include:

job sheets

patterns

plans

drawings and sketches

verbal or illustrated directions from supervisor

number and type of objects to be produced

quality requirements.

OHS&E requirements

What can OHS& E requirements include?

OHS&E requirements may include:

equipment safety instructions

hazardous and dangerous goods codes

local safe operating procedures

specific workplace rules regarding personal protective wear and equipment.

environmental controls

risk assessment

emergency procedures

What can a suitable work area include?

A suitable work area may include:

on-site host company maintenance or tooling workshop

simulated workshop in RTO

on-site production facilities

What can appropriate tools, equipment and materials include?

Appropriate tools will vary according to the project, but may include:

manual saw

jigsaw

hacksaw

clamp

hammer

mallet

screw driver

punch

pliers and pincers

file

miter cutter

90 degree angle

staple gun

paintbrush

rags

measuring tapes/ rulers

spirit level

bevel

chisel

rollers/scissors

Appropriate equipment could include:

electric saw

electric sander

electric screw driver

power drills

vertical drill presses

pedestal grinders

plastics processing equipment

plastics welders such as hot air guns, ultrasonic

injection moulders/blow moulders/rotational moulding equipment/thermoforming equipment

Appropriate materials could include:

plastics raw material

extruded plastic sheeting ( e.g. perspex, acrylic, polycarbonate)

adhesives

screws

bolts

glue

hinges and metal fasteners

sandpapers

primers

paints

What could potential hazards include?

Potential hazards may include:

broken or faulty equipment

unnoticed sharp objects

poor lighting

inadequate ventilation

inadequate attention to the activities of others

electrical shortages and power overload

disorganised or cluttered workspace (poor housekeeping)

poor attention when dealing with tools and equipment.

environmental chemicals, heat, dust, noise, gas and oil

hot equipment and materials

cuts

back strain

What could records include?

Records could include:

plant and maintenance records

set up, date, batch and materials

check sheets

reporting requirements

documenting equipment and/or material defects

workplace procedures relating to the use of tools and equipment.

equipment booking forms and records

attendance records

quality reports

production reports

log sheets

What could specifications include?

Specifications could include:

measurements and dimensions

shape

joining methods

quality standard

materials to be used

appearance

colour/finish

What is involved in making sure plastic pieces are joined?

Plastic pieces can be joined together by:

glue

ultrasonic/hot air welding

clips

metal fasteners ( e.g. screws, bolts, rivets.).

What is involved in making sure non-conformities are rectified?

Rectifying non-conformities could involve:

disassembly of the furniture item

reshaping /resizing or re-cutting component materials

reassembly

refinishing

adjusting process conditions.

What is involved in making sure work is finished?

Finishing work can include:

sanding

priming

painting

decorating.

assembly

polishing

trimming

Unit sector

Manufacturing Pathways

This unit contains employability skills.